Claims:

1. A method for processing cocoa beans comprising: adding water to a
plurality of cocoa beans to form a suspension; wet grinding said cocoa
bean water suspension in a first grinding step in a first mill; wet
grinding said cocoa bean water suspension in a second grinding step in a
second mill; heating said cocoa bean water suspension to a temperature of
approximately 70 degrees Celsius or less; decanting said cocoa bean water
suspension such that said suspension is separated into three phases, a
water phase, a fat phase, and solids.

2. A method for processing cocoa beans comprising: adding water to a
plurality of cocoa beans to form a mixture; fine grinding the cocoa
bean/water mixture; heating the finely ground cocoa bean/water mixture to
a temperature of approximately 70 degrees Celsius or less; decanting the
cocoa bean mixture/suspension to separate larger solids from liquid;
separating smaller and/or fine solid particles from liquids and/or
separating oil products from non-oil products.

3. The method according to claim 1 further including a step wherein said
solids are dried in a dryer after separation in said decanting step to
obtain aromatics and cocoa solids.

4. The method according to claim 1 further including a step wherein
material obtained as said water phase is processed in a two phase
separator to remove fine particles from said water phase.

5. The method according to claim 1 further including a step wherein said
water phase is subjected to a first concentration step to obtain
aromatics.

6. The method according to claim 5 further including a step wherein said
water phase is subjected to a second concentration step to obtain
polyphenols.

7. The method according to claim 1 further including a step wherein said
fat phase is filtered on a vibrating screen to remove substantial solids.

8. The method according to claim 1 further including a step wherein said
fat phase is further processed in a three phase separator to remove
excess water and remaining solids.

9. The method according to claim 1 further including a step wherein said
fat phase is filtrated and cocoa butter is obtained.

10. The method according to claim 1 or 2 wherein cocoa butter is produced
and when said cocoa butter exits said decanting step, said cocoa butter
is caused to exit at a temperature selected from between approximately 45
and 50 degrees Celsius.

11. The method according to claim 1 or 2 wherein cocoa powder is produced
which said cocoa powder is dried at a temperature selected from between
approximately 55 and 70 degrees Celsius.

12. The method according to claim 1 wherein said first grinding step is
performed with a perforated disc mill.

13. The method according to claim 1 wherein said second grinding step is
performed with a toothed colloid mill.

14. The method according to claim 1 wherein said second grinding step is
performed with a corundum stone mill.

15. The method according to claim 1 wherein after said first grinding
step, a pump pumps said cocoa bean water suspension to a location wherein
said second grinding step is performed.

16. The method according to claim 1 wherein during said heating step,
said cocoa bean water suspension is heated utilizing a tube heat
exchanger.

17. The method according to claim 1 wherein prior to one or more wet
grinding steps, sugar and/or fruit juices are added to the cocoa bean
water suspension or mixture.

18. The method according to claim 1 further including an additional step
where wet solids are treated with a heatable roll grinder to reduce
particle size and begin pre-drying.

19. The method according to claim 1 further including a step in which
sugar, sugar solution, and/or fruit juices are added to extracted cocoa
solids before drying.

20. The method according to claim 1 wherein extracted cocoa solids are
dried on a vacuum belt dryer following separation in said decanting step.

22. The method according to claim 1 wherein heavy phase(s) are treated by
a two phase separator and a vacuum rotation filter to remove fine
particles.

23. The method according to claim 1 wherein prior to one or more grinding
steps, said cocoa beans are broken to form cocoa nibs.

24. The method according to claim 1 or 2 wherein in one or more grinding
steps, said cocoa bean water suspension or mixture is ground to include
cocoa bean particle sizes of substantially no more than approximately 10
micrometers or less.

25. The method according to claim 2 wherein when at least two grinding
steps are performed, a coarse grinding of said cocoa bean water mixture
is performed prior to said fine grinding step.

26. The method according to claim 1 or 2 wherein said cocoa processing
steps are performed without use of non-water solvents.

27. The method according to claim 1 or 2 wherein each of said cocoa
processing steps are performed at temperatures of no more than
approximately 70 degrees Celsius.

28. A chocolate construction kit including a plurality of cocoa bean
extraction products produced in accordance with method steps set forth in
claim 1 or 2.

29. A chocolate construction kit according to claim 28 which includes at
least aromatics, cocoa butter, cocoa powder, and polyphenols.

Description:

RELATED APPLICATION DATA

[0001] This application claims the benefit of priority of U.S. Patent
Application No. 61/140,844, filed on Dec. 24, 2008 and similarly titled.
The entirety of such application is hereby incorporated by reference.

[0003] The types of methods and the steps employed for processing cocoa
beans into their respective food products have a significant influence on
the various qualities of the resulting cocoa product(s) such as with
respect to flavor, intensity, or anti-oxidant or vitamin content and even
yield. For this reason, the method employed for processing cocoa beans
into cocoa products (such as food stuffs) can be critically important to
the commercial viability or success or acceptance of such products (in
the marketplace, or in use for enhancement of other products).

[0004] A typical cocoa bean processing procedure begins with the harvest
of the beans followed by the fermenting and drying of the cocoa beans.
Afterwards, the beans are typically cleaned and roasted. Once prepared
for further processing, the cocoa beans, in conventional or prior art
methods, are subjected to processing techniques such as those described
in Patent Publication No. PCT/JP2002/012064 (hereinafter "the '064
method" or "the '064 publication").

[0005] Although believed to reflect at least one convention in cocoa bean
processing techniques, the processing methods employed in the '064
publication have one or more drawbacks or deficiencies and/or otherwise
do not fulfill all of the desirable needs in the subject art. For
example, the '064 method results in a destruction of cellular
compartments of the raw cocoa materials due to high mechanical loads or
shear stresses and/or high heat employed which aids in the extraction of
cocoa fats. Specifically, using the '064 method, frictional heat
generated by the mechanical extraction techniques liquefies the cocoa fat
and forms a chocolate liqueur. Using this technique, however, results in
emulsification of oil-fat fractions which, in turn, complicates later
desirable phase separation processes and/or steps by which important or
desirable cocoa products can otherwise be obtained. In particular,
separation of the oil-fat phase becomes difficult or even impossible
after emulsification without the use of undesirable solvents such as
hexanol (i.e., water is generally useless as a solvent after
emulsification). Furthermore, obtaining or retaining desirable flavors
and/or cocoa products such as aromatics, anti-oxidants, and/or vitamins
becomes difficult or is otherwise inefficient using the '064 method.

[0006] In view of the above enumerated drawbacks and/or desires for
improvements in the art, it is a purpose of the herein described
invention to address one or more of such drawbacks and/or desires as well
as, or in the alternative, other needs which will become more apparent to
the skilled artisan once given the present disclosure.

SUMMARY OF CERTAIN EMBODIMENTS OF THE INVENTION

[0007] Generally speaking, the present invention is directed to techniques
for processing and/or extracting material from cocoa beans. In certain
embodiments, the invention relates to methods for processing cocoa beans
which utilize water which is otherwise considered undesirable in cocoa
bean processing techniques. In still other embodiments, the invention
relates to methods for processing cocoa beans which utilize lower
processing temperatures either with or without water addition steps. In
some embodiments of the invention, methods for producing virgin or extra
virgin cocoa products are provided in which loss or damage or
deterioration of cocoa bean products or materials (e.g., aromatics,
polyphenols, vitamins etc.) during processing is reduced. In at least one
embodiment, a method for producing cocoa intermediate products such as
cocoa butter is provided. In other embodiments, chocolate product
"construction kits" are provided which, for example, can include
different elements for making chocolate. In certain example kits,
aromatics, cocoa butter, cocoa powder, and/or polyphenols are included.
Using such kits, different elements in different mixtures or quantities
can be combined, as desired, in order to determine aroma qualities,
content of fat, health effects, and/or other characteristics of the
chocolate or other cocoa products produced.

[0008] In one non-limiting embodiment of the invention, a method for
processing cocoa beans which employs relative low heat, low shear forces,
and/or permits use of water as an extraction solvent is provided. In
these or alternative embodiments, improvement(s) in taste of cocoa
products are achieved (e.g., they are less bitter which results in
reduced need for sugar) and/or improved retention of anti-oxidants and/or
fat soluble vitamins (for health benefits) is obtained. In certain
embodiments, using lower processing temperatures, for example,
preservation of higher quantities of the original or primary components
of the cocoa bean, including preservation of roasting or aroma components
is achieved. In further embodiments, extraction of aromatics and/or
polyphenols (for use in creation and/or refinement of food and non-food
products) is obtained.

[0009] In one exemplar, non-limiting embodiment of the subject invention,
therein is provided a method for processing cocoa beans comprising:

[0023] In at least one embodiment, the initial breaking of whole cocoa
beans is accomplished using a hammer mill. In the same or a different
embodiment, a colloid mill is used in an initial (e.g., course) grinding
step and/or a corundum stone mill is employed in a later (e.g, fine)
grinding step. Notably, however, any mill can be used that results in a
particle size generally equal to or under approximately 40 micrometers,
more preferably equal to or less than 30 micrometers, and most preferably
equal to or less than 10 micrometers. In either or both of these steps,
undesirably high pressures and/or mechanical forces are not required or
employed and therefore undesired levels of emulsification of cocoa bean
material does not occur. In certain particularly preferred but
non-limiting embodiments, cocoa beans are ground to particle sizes of
approximately 10 μm or smaller. Employing such particle sizes in such
embodiments enables a water solvent to properly wet the material (because
of increased surface area) which, in turn, results in better extraction
results (e.g., better yields of desirable cocoa bean materials such as
fats or lipids, aromatic substances, and/or polyphenols).

[0024] In certain non-limiting embodiments, in a heating step,
liquefaction of cocoa butter is obtained and/or improved mechanical phase
separation is achieved. In different or related embodiments, a decanting
step employing centrifugal forces is employed. In such a step, larger
particles are generally separated from liquid. Moreover, solids separated
in this step may be dried (e.g., for use in chocolate production or
processing). In certain embodiments, in a second separation step, removal
of smaller or fine particles from liquid is achieved. In such a step, oil
based products such as cocoa butter and/or hydrophobic aromatic
components can be or are separated from liquid phase components such as
cocoa extract and/or hydrophilic aromatic products and/or polyphenol
components.

[0025] In certain preferred but non-limiting embodiments, if there is
microorganism spoilage of cocoa extracted materials (e.g., cocoa butter),
such material can be deodorized employing a vacuum de-aerator. In other
preferred example embodiments, if microorganism decontamination occurs, a
high pressure treatment such as pascalisation is possible (e.g., which
can preserve aromatic compounds). In embodiments in which microorganism
spoilage and contamination occurs, heat treatment and deodorization may
be employed.

[0026] In still further embodiments, a separated liquid phase (e.g.,
degreased cocoa extract) can be further treated to remove undesired
water. This may be achieved using evaporation techniques which, when
employed, can desirably, result in water suspended flavor compounds.
Moreover, concentrated polyphenols may result. In yet still further
embodiments, recovered cocoa flavors may be enhanced by reverse flow
distillation (e.g., to separate flavor components from water).

[0027] In certain embodiments, water which results from the above or
related non-limiting embodiments (gained by decantation, separation,
and/or evaporation) may be sterilized and/or tyndallized (to kill spores)
such as by heat to prevent microorganism spoilage and/or propagation
and/or may be deodorized by vacuum de-aerator.

[0028] In one embodiment of a method or technique according to the herein
described invention, "fixed phase" (e.g., using an absorber), "water
phase", and "oil phase" fractions are each extracted and separated after
fine grinding of the cocoa beans in a single process step. In further
process steps in such embodiment, the fractions are purified and
separated into products such as dried and extracted cocoa powder, cocoa
butter with hydrophobic cocoa flavor, hydrophilic cocoa flavor, and
polyphenol concentrate.

[0029] In yet another exemplar, non-limiting embodiment of the subject
invention, therein is provided a method for processing cocoa beans
comprising:

[0030] adding water to a plurality of unfermented, fermentedand/or
pre-dried and/or roasted cocoa beans to form a suspension;

[0031] wet grinding said cocoa bean water suspension in a first grinding
step in a first mill;

[0032] wet grinding said cocoa bean water suspension in a second grinding
step in a second mill;

[0033] heating said cocoa bean water suspension to a temperature of
approximately 70 degrees Celsius or less;

[0034] decanting said cocoa bean water suspension such that said
suspension is separated into three phases, a water phase, a fat phase,
and solids.

[0035] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said solids are dried in a dryer after
separation in said decanting step to obtain aromatics and cocoa solids.

[0036] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein material obtained as said water phase is
processed in a two phase separator to remove fine particles from said
water phase.

[0037] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said water phase is subjected to a first
concentration step to obtain aromatics.

[0038] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said water phase is subjected to a second
concentration step to obtain polyphenols.

[0039] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said fat phase is filtered on a vibrating screen
to remove substantial solids.

[0040] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said fat phase is further processed in a three
phase separator to remove excess water and remaining solids.

[0041] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step wherein said fat phase is filtrated and cocoa butter is
obtained.

[0042] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
cocoa butter is produced and when said cocoa butter exits said decanting
step, said cocoa butter is caused to exit at a temperature selected from
between approximately 45 and 50 degrees Celsius.

[0043] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
cocoa powder is produced which said cocoa powder is dried at a
temperature selected from between approximately 50 and 70 degrees
Celsius.

[0044] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
said first grinding step is performed with a perforated disc mill.

[0045] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
said second grinding step is performed with a toothed colloid mill.

[0046] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
said second grinding step is performed with a corundum stone mill.

[0047] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
after said first grinding step, a pump pumps said cocoa bean water
suspension to a location wherein said second grinding step is performed.

[0048] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
during said heating step, said cocoa bean water suspension is heated
utilizing a tube heat exchanger.

[0049] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
prior to one or more wet grinding steps, sugar and/or fruit juices and/or
cocoa pulp are added to the cocoa bean water suspension or mixture.

[0050] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including an additional step where wet solids are treated with a heatable
roll grinder to reduce particle size and begin pre-drying.

[0051] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided further
including a step in which sugar, sugar solution, and/or fruit juices
and/or cocoa pulp are added to extracted cocoa solids before drying.

[0052] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
extracted cocoa solids are dried on a vacuum belt dryer following
separation in said decanting step.

[0053] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein a
drying step produces aromatics and/or cocoa solids.

[0054] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
said heavy phase is treated by a two phase separator and a vacuum
rotation filter to remove fine particles.

[0055] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
prior to one or more grinding steps, said cocoa beans are broken to form
cocoa nibs.

[0056] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
in one or more grinding steps, said cocoa bean water suspension or
mixture is ground to include cocoa bean particle sizes of substantially
no more than approximately 10 micrometers or less.

[0057] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
when at least two grinding steps are performed, a coarse grinding of said
cocoa bean water suspension or mixture is performed prior to a fine
grinding step.

[0058] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
said cocoa processing steps are performed without use of non-water
solvents.

[0059] In a further embodiment according to or in combination with any one
of the preceding or following embodiments, a method is provided wherein
each of said cocoa processing steps are performed at temperatures of no
more than approximately 70 degrees Celsius (e.g., possibly except for
optional pasteurization or conventional drying steps to treat extracts if
needed).

[0060] In at least one embodiment, a chocolate construction kit including
a plurality of cocoa bean extraction products produced in accordance with
method steps set forth in any one of the preceding embodiments is
provided. In at least one of such example embodiments, such a chocolate
construction kit includes, as part of the kit, aromatics, cocoa butter,
cocoa powder, and/or polyphenols and/or vitamins.

[0061] Certain examples of the invention are now below described with
respect to certain non-limiting embodiments thereof as illustrated in the
following drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

[0062] FIG. 1 schematically illustrates an embodiment of one exemplar
cocoa processing technique according to the subject invention.

[0063] FIG. 2 schematically illustrates an embodiment of an alternative
cocoa processing technique according to the subject invention.

[0076] FIG. 15 illustrates example mass percentages of cocoa products
which may be obtained when performing one or more of the herein described
cocoa bean processing techniques.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0077] For a more complete understanding of the present invention,
reference is now made to the following description of various
illustrative and non-limiting embodiments thereof, taken in conjunction
with the accompanying drawings in which like reference numbers indicate
like features.

[0078] Generally speaking, this invention relates, in certain non-limiting
embodiments, to methods for processing cocoa beans in which less
destruction or loss or damage to naturally occurring cocoa bean materials
or compounds or elements (e.g., aromatics, polyphenols, etc.) occurs.
Employing such methods, virgin or extra-virgin type cocoa products (e.g.,
final products such as chocolate or intermediate products such as cocoa
butter) may be obtained or produced. In one or more of such cocoa bean
processing methods, water is utilized which, prior to Applicants'
discovery of the inventive techniques discussed herein, has otherwise
been considered undesirable in conventional cocoa bean processing
techniques. In still other embodiments, such methods for processing cocoa
beans utilize lower processing temperatures either with or without water
addition steps.

[0079] For example, in certain embodiments of the subject invention, after
adding water to a plurality of cocoa beans to form a mixture or
suspension and then fine grinding the cocoa bean/water suspension or
mixture, the suspension (or mixture) is heated, in further processing
steps, to a temperature of preferably no more than approximately 70
degrees Celsius. Afterwards, the mixture or suspension is decanted to
separate larger solids from liquid(s) and then smaller and/or fine solid
particles are further separated from liquids and/or oil products are
separated from non-oil products.

[0080] In certain more specific example embodiments, fermented and/or
non-fermented and/or pre-dried and/or roasted cocoa beans (or nibs) are
put into suspension and then wet grinded (e.g., optionally with further
water) in a perforated disc mill. Subsequently, a pump conveys the milled
suspension to a toothed colloid mill for a second or fine grinding step.
Afterwards, the suspension is heated by passing it through a tube heat
exchanger so that it reaches a temperature of approximately 70° C.
and then it is delivered to a decanter. In the decanter, the suspension
is separated into three phases, the heavy phase (water phase), the light
phase (fat phase), and the solid phase. The solid phase or solids are
dried in a drum dryer preferably, but not necessarily, immediately after
the separation which occurs in the decanter. In particular, aromatics and
cocoa solids may be gained through such drying process. The heavy phase
is further processed in a two phase separator to remove the finest
particles out from the suspension. Aroma recovery takes place in a
subsequent concentrator at the same time the water (or heavy) phase is
pre-concentrated. In another processing step, the pre-concentrated
suspension is further concentrated to obtain polyphenols or polyphenol
concentrate. The light phase is filtered employing a vibrating screen to
remove the rough solids and then is processed in a three phase separator
where the removal of excessive water and solids takes place. The
resulting light phase is then filtered once again and cocoa butter is
obtained.

[0081] Optionally, in certain embodiments, prior to one or more wet
grinding steps, sugar and/or fruit juices are added to the cocoa bean
water suspension or mixture. Further optionally, a corundum mill or other
mill type may be used for the second or fine grinding step (i.e., of
course, any mill or mills may be employed in any number of steps so long
as desirably small particle sizes are obtained). In other optional
embodiments, wet solids are treated with a heatable roll grinder to
reduce particle size and begin pre-drying. Moreover, sugar, sugar
solution, and/or fruit juices may optionally be added to extracted cocoa
solids before drying to improve flavor development during the drying
process. The solids may also be optionally dried on a vacuum belt dryer
substantially immediately (or some other desirably short time) after
separation in the decanter. Also optionally, the heavy phase may be
treated by a two phase separator and a vacuum rotation filter to remove
fine particles.

Example 1

[0082] Referring now to FIG. 1, a detailed exemplar embodiment of a
technique for processing cocoa beans is illustrated therein (i.e., as a
flow chart illustrating the various steps in one example inventive method
of processing cocoa beans). As illustrated in FIG. 1, the subject cocoa
processing technique generally begins with fermented cocoa beans which
are subsequently subjected to a "breaking" step during which the beans
are broken into smaller, non-whole bean particles (e.g., cocoa nibs),
and, after which, water is added to form a coffee bean particle mixture
or suspension. Following these steps, the bean particles are subjected to
further particle size reduction steps which preferably, but not
necessarily, result in bean particle sizes of approximately 10 μm or
smaller (this is in contrast to certain prior art processing techniques
where much larger particle sizes are often employed). Reducing the bean
particles to such a size range substantially increases the exposed
surface area of the bean particle material therefore allowing it to be
more efficiently wet (e.g., with water rather than a chemical solvent)
for improved extraction results. Bean particle size reduction, in this
regard, is accomplished (in this example embodiment) using, first, a
colloid mill, and then, afterwards, a corundum stone mill. In particular,
neither of these particle size reduction steps result in significant
frictional heat production or too high of mechanical forces being
employed such that undesirable emulsification occurs. Of course, other
particle size reduction steps can be employed.

[0083] Following these particle size reduction steps, and as illustrated
in FIG. 1, the cocoa materials are subjected to a heating step (in a heat
exchanger at approximately 60 degrees Celsius) during which a cocoa
butter liquefaction is obtained and/or improved mechanical phase
separation is achieved. Afterwards, a decanting step is employed during
which centrifugal forces are utilized to achieve particle separations. In
particular, larger particles in this step are generally separated from
liquid (in approximate percentages shown in the subject figure).
Moreover, solids separated in this step may be dried. Following the
decanting step, in a second two-phase separator step and a third
three-phase separator step, removal of smaller or fine particles from
liquid is achieved (in approximate percentages shown in the subject
figure). In such steps, oil based products such as cocoa butter and/or
hydrophobic aromatic components can be or are separated from liquid phase
components such as cocoa extract and/or hydrophilic aromatic products
and/or polyphenol components. In the embodiment illustrated, for example,
approximately 6% mass liquid cocoa butter is achieved with approximately
43% mass being associated with aromatics, concentrated polyphenols, and
water.

[0084] If there is microorganism spoilage of cocoa extracted materials
(e.g., cocoa butter), such material can be deodorized employing a vacuum
de-aerator. Moreover, if microorganism contamination occurs, a high
pressure treatment such as pascalisation is possible (e.g., which is
desirable because it can preserve aromatic compounds). However, if both
microorganism spoilage and contamination occurs, heat treatment and
deodorization may be employed (and are possibly recommended).

[0085] If desired, a separated liquid phase (e.g., degreased cocoa
extract) can be further treated to remove undesired water. This may be
achieved using evaporation techniques which, when employed, can desirably
result in water suspended or containing flavor compounds (e.g., to be
marked as flavored water). Moreover, concentrated polyphenol products may
be obtained. Still furthermore, although such step is not illustrated in
FIG. 1, recovered cocoa flavors may be enhanced by reverse flow
distillation (e.g., to separate flavor components from water) therefore
making them more desirable and/or valuable.

Example 2

[0086] Turning now to FIGS. 2 through 6, another example embodiment of a
method for processing cocoa beans is illustrated therein. Certain example
steps in such a process are set forth as follows:

Grinding and suspending: In a grinding and/or suspending step, cocoa
beans (e.g., unfermented, fermented, pre-dried, and/or roasted beans) or
nibs are combined or suspended with water. Thereafter, optionally using a
pump, the mixture or suspension is ground in at least a first grinding
step using a perforated disc mill and/or a toothed colloid mill. Fine
grinding: In at least one fine grinding step, cocoa bean cells are
macerated. This enables the solvent (water) to wet the cocoa bean
material better due to increased available surface area of the macerated
cocoa beans. Heating: In a heating step, optionally using a tube heat
exchanger, liquefaction of cocoa butter is achieved by heating (e.g.,
between 45-70 degrees Celsius). Moreover, improvement of mechanical phase
separation is achieved. Decanter: In at least one decanting step, solids
are separated from the liquid phase by centrifugal forces. In this step,
primarily coarse or large or high mass solids will be removed.
Additionally, the liquid phase may be separated from the light phase (oil
phase) and the heavy phase (water phase). Vibrating screen: In a
filtering phase, a vibrating screen is used to remove further coarse
solids from the separated light phase and heavy phase. Two phase
separator: Employing a two phase separator, fine particles may be removed
from the heavy phase. Concentrator: In a concentration phase,
pre-concentration of the heavy phase and aroma recovery is performed.
Further, water and certain flavor compounds are evaporated. Additionally,
enhancement of cocoa flavors may be achieved using reverse flow
distillation (i.e., to separate flavor compounds and water).
Concentrator: In an optional second concentration phase, evaporation of
excessive water is performed. In this step, concentration of water
soluble polyphenols and other ingredients (e.g., vitamins) occurs. Three
phase separator: In a three phase separator, fine particles are removed
from the light phase and excessive water is separated from the oil phase.
Plate Filter: In an optional plate filter phase, additional fine
particles are removed from the light phase and additional water is
separated from the oil phase. In some embodiments, cocoa butter results
in this phase. Drum dryer: In a drying step, excess or unwanted water can
be removed and aroma recovery performed or a roasting effect achieved. In
certain embodiments, this step may produce an aroma phase and/or dry
cocoa matter.

Example 3

[0087] Referring now to FIGS. 7, 8, and 12, an alternative process to the
one described above is disclosed. Exemplifying the primary (or all)
differences between the above-described embodiment and that shown in the
subject figures, certain additional and/or modified steps in the process
are set forth as follows:

Supplemental to the "Grinding and suspending" step or phase described
above, fruit juices and/or sugar is added to the cocoa bean/water mixture
or suspension. Such mixture or suspension is then ground or macerated as
otherwise described above. Grinding may be performed using a corundum
stone mill (e.g., rather than using a toothed colloid mill). Vacuum
Rotation Filter: Subsequent to the "Two phase separator" step or phase
described above, a filtration step is performed in which fine particles
are removed from the heavy phase to reduce the cloudiness of the liquid.
Heatable roll grinder: In a combined heating and grinding step, a
heatable roll grinder is used to remove excess or undesired water and to
reduce particle size. Conche: In a conching step, excess or undesired
water is removed, aroma recovery takes place, and a roasting effect is
achieved. Optionally, additional tailoring of flavor or development of
flavor is performed by adding one or more of sugar and/or fruit juices.
Moreover, an emulsifying agent may be added.

Example 4

[0088] Turning now to FIGS. 9 and 11, a still further alternative process
for processing cocoa beans is illustrated. As contrasted to the
above-described example embodiments, subsequent to a "Heatable Roll
Grinder" step or phase similar to the step described with respect to
Example 3, a belt dryer is used in this illustrated process. Using such a
belt dryer, excess or undesired water is removed and aroma recovery and
roasting effects are obtained. In this step, vacuum and condensation may
be utilized. Furthermore, flavor may be tailored in this step (alone or
in addition to in other steps) by addition of sugar or fruit juices, for
example (other flavor changing materials or substances may, of course, be
added). In this stage, both aromatics and dry cocoa matter may be
obtained.

Example 5

[0089] Referencing now FIGS. 13 and 14, an additional alternative
embodiment of a cocoa processing method is disclosed. Although the
process in these figures resembles that process disclosed in FIG. 7,
certain significant differences between the processes are apparent. In
particular, as seen best in FIG. 14, sugar, water, and fruit juices are
added to cocoa solids prior to the solids being processed or treated in a
heatable roll grinder. Furthermore, cocoa butter and an emulsifying agent
are added in the conching phase. Similar to the process disclosed in FIG.
12, however, employing these steps, aromatics and/or dry cocoa matter
and/or chocolate may be obtained.

[0091] Although not intended to be limiting in any respect, FIG. 15 is
provided in this application to illustrate example mass percentages of
cocoa products which may be obtained when performing one or more of the
herein described cocoa bean processing techniques.

[0092] Once given the above disclosure, many other features,
modifications, and improvements will become apparent to the skilled
artisan. Such features, modifications, and improvements are therefore
considered to be part of this invention, without limitation imposed by
the example embodiments described herein. Moreover, any word, term,
phrase, feature, example, embodiment, or part or combination thereof, as
used to describe or exemplify embodiments herein, unless unequivocally
set forth as expressly uniquely defined or otherwise unequivocally set
forth as limiting, is not intended to impart a narrowing scope to the
invention in contravention of the ordinary meaning of the claim terms by
which the scope of the patent property rights shall otherwise be
determined.